Flow diverter

ABSTRACT

A flow diverter comprises a surface to divert fluid flow within oil and gas wellbore equipment exposed to flows of abrasive, corrosive, or otherwise deleterious fluids, such as those used in hydraulic fracturing. The diverter may comprise a concave surface used to limit damage to surfaces within components used to connect a frac manifold to a frac tree or to prevent the flow of fracturing fluid from a frac manifold to a frac tree.

TECHNICAL FIELD

The present disclosure relates generally to oil or gas wellbore equipment, and, more particularly, to a flow diverter which may be used in conjunction with components exposed to flows of abrasive, corrosive, or otherwise deleterious fluids, such as those used in hydraulic fracturing.

BACKGROUND

Within the field of oil and gas exploration and production, there are many applications in which abrasive or corrosive fluids must be moved from one point to another. These substances are often transported through components manufactured using carbon steel or other materials that may be particularly susceptible to being damaged by certain types of fluids. The risk of damage is generally increased if there are particular surfaces within a flow conduit which are orthogonal to the direction of flow within another portion of the conduit.

Further, abrasive or corrosive fluids may be transported under high-pressure and/or high-velocity conditions, which can increase the risks of damage to the components through which the fluids are flowing. The risk of damage may be further increased if the components through which the fluids are flowing are configured such that turbulent flow is created within the flow conduits. In addition, certain components disposed within fluid conduits, such as elastomeric seals may be particularly susceptible to being damaged by abrasive or corrosive fluids.

For all these reasons, when transporting fluids that are abrasive, corrosive, or otherwise deleterious, it may be advantageous to divert the flow of such fluids in order to decrease velocity, reduce turbulence, limit the instances of surfaces being impacted by orthogonal fluid flow, and/or prevent or reduce contact between the fluids and particularly fragile or sensitive components.

One particular application involving the transport of abrasive, corrosive, or otherwise deleterious fluids is hydraulic fracturing performed as part of the process of producing oil and gas from an underground formation. For example, frac manifolds, also referred to herein as zipper manifolds, are designed to allow hydraulic fracturing operations on multiple wells using a single frac pump output source. Frac manifolds are positioned between the frac pump output and frac trees of individual wells. A frac manifold system receives fracturing fluid from the pump output and directs it to one of many frac trees. Fracturing fluid flow is traditionally controlled by operating valves to isolate output to a single tree for fracking operations.

Frac zipper manifolds may be rigged up to frac trees before frac equipment arrives at the well site. Once onsite, the frac equipment need only be connected to the input of the frac manifold. Because individual frac trees do not need to be rigged up and down for each fracking stage and because the same frac equipment can be used for fracking operations on multiple wells, zipper manifolds reduce downtime for fracking operations while also increasing safety and productivity. Another benefit includes reducing equipment clutter at a well site.

Despite their benefits, further efficiencies and cost savings for zipper manifolds may be gained through improved designs. In particular, typically treatment fluid in the zipper manifold passes to frac trees via goat heads or frac heads and frac iron, but there are several drawbacks to using such setups to span the distance between the zipper manifold and each frac tree. Goat heads, or frac heads, traditionally employ multiple downlines and restraints that clutter the area between the zipper manifold and the frac tree, which can make for a more difficult and less safe work environment to operate and maintain the frac equipment.

Some designs have been developed to avoid using frac iron. One design uses a single line made from studded elbow blocks and flow spools with swiveling flanges. Such a design is disclosed in, for example, U.S. Pat. Nos. 9,932,800, 9,518,430, and 9,068,450. A similar design is currently offered for sale by Cameron International of Houston, Tex., under the brand name Monoline. One drawback of this design is that the weight of the equipment combined with the potentially awkward orientation of the lines can make installation difficult and can place uneven or increased stress on the connections to the frac manifold and/or the frac tree. Another drawback is that using a single line to connect the frac manifold to the frac tree can lead to increased velocity and turbulence of the flow, when compared to using multiple lines. Such conditions may lead to a greater risk of erosion in the frac tree. Replacing a damaged frac tree can be very expensive and time-consuming.

Due to the velocity and turbulence of flow within the components used to connect a frac manifold to a frac tree, this is an application in which the use of a flow diverter may be particularly advantageous. Such use of a flow diverter is explained below in greater detail, and also in U.S. Pat. No. 11,091,993 to Sizemore, et al. The Sizemore '993 patent is hereby incorporated by reference, particularly with respect to its discussion of flow diverter 300 as shown in FIGS. 6A, 6B and 8 , and flow diverter 310 as shown in FIGS. 7A-8 .

Similarly, a flow diverter may be used in a device intended to prevent the flow of fracturing fluid from a frac manifold to a frac tree. Such use of a flow diverter is explained below in greater detail, and also in US Patent Publication No. 2021/0047907 to Sizemore, et al. The Sizemore '907 application is hereby incorporated by reference, particularly with respect to its discussion of compression member 1700 as shown in FIGS. 13-15 .

SUMMARY OF THE INVENTION

Within the interior of flow components, particularly those used in hydraulic fracturing operations, a diverter is used to redirect the flow of fluids that may be abrasive, corrosive, or otherwise deleterious. The diverter comprises a surface that is oblique in relation to the central longitudinal axis of the adjacent flow component. The surface of the diverter may be generally concave. The use of the flow diverter may decrease velocity, reduce turbulence, and limit the instances of interior surfaces of the flow component being impacted by orthogonal fluid flow

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present disclosure will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the disclosure. In the drawings, like reference numbers may indicate identical or functionally similar elements.

FIG. 1 illustrates one embodiment of a dual spool connection from a zipper manifold to a frac tree.

FIG. 2 illustrates a dual spool connection including three flow diverters mounted on blind flanges.

FIGS. 3A-3B illustrate the bi-directional flow diverter shown in FIG. 2 .

FIGS. 4A-4B illustrate the uni-directional flow diverter shown in FIG. 2 .

FIG. 5 illustrates a frac manifold isolation tool including a bottom surface comprising a flow diverter.

FIG. 6 illustrates the omni-directional flow diverter shown in FIG. 5 .

FIG. 7 illustrates the frac manifold isolation tool of FIG. 5 after the cup tool and flow diverter have been moved into the operative position.

DETAILED DESCRIPTION

FIG. 1 illustrates an exemplary embodiment of a well configuration unit 210 with a bridge connector header 230. The bridge connector header 230, which connects to a frac tree, forms a “T” junction 215 with a short spool 238 a extending upward from valve 102 a and 102 b, and two additional short spools 238 b extending from either side of bridge connector header 230.

The T-junction 215 of the bridge connector header 230 connects to two studded blocks 250. Each studded block 250 joins to a bridge spool 255 that connects similarly to studded blocks 250 and a frac tree header 270 on the frac tree 290.

Fluid flowing through short spool 238 a is traveling along the y-axis, as shown in FIG. 1 . The T-junction 215 formed by bridge connector header 230 splits the fluid flow into two streams, each of which travel along the z-axis to one the two studded blocks 250. Because the y-axis is orthogonal to the z-axis, the flow has a tendency to become turbulent as it shifts from the y-axis to the z-axis. This turbulence, as well as other dynamic flow characteristics of this configuration, can lead to increased erosion and premature failure of bridge connector header 230 and short spools 238 b. In addition, if fluid flows straight through bridge connector header 230 such that it orthogonally impacts the inner surface of blind flange 236, that surface will be particularly susceptible to erosion.

Referring to FIG. 3A, flow diverter 300 may be mounted on blind flange 236. As shown in FIG. 2 , flow diverter 300 extends downward from blind flange 236, such that it is disposed within the flow of fracturing fluid from short spool 238 a. Flow diverter 300 may be generally cylindrical with diverting surfaces 302 and 304. In this configuration, the central axis of flow diverter 300 may be substantially aligned with the central axis of short spool 238 a, which is coincident with the y-axis. Diverting surfaces 302 and 304 may be curvilinear and are preferably concave, as shown in FIG. 3B. Alternatively, diverting surfaces 302 and/or 304 may be convex, planar, or any other configuration, provided that the surfaces divert the fluid flowing through short spool 238 a to travel in a direction other than along the y-axis. This redirection may decrease the turbulence of the flow as it shifts from the y-axis to the z-axis, and thus decrease the erosion of bridge connection header 230 and short spools 238 b.

Studded blocks 250 are elbow-shaped to redirect the flow streams from the z-axis to the x-axis, which is coaxial with bridge spools 255. The frac fluid travels through the bridge spools 255 to the studded blocks 250 on the frac tree side, and the two flows are rejoined at the frac tree header 270 of the frac tree 200. Although splitting the flow into two streams results in lower velocities and reduced turbulence within frac tree 200, the interior surfaces of studded blocks 250 are still subject to significant risks of erosion.

Referring now to FIG. 4A-4B, either or both blind flange 240 may include flow diverter 310, with diverting surface 312. Flow diverter 310 may be generally cylindrical with a central axis along the z-axis, as shown in FIG. 4A. Diverting surface 312 may be curvilinear and is preferably concave. Alternatively, diverting surface 312 may be convex, planar, or any other configuration, provided that the surface diverts the fluid flowing through short spools 238 b to travel in a direction other than along the z-axis. This redirection may decrease the turbulence of the flow as it shifts from the z-axis to the x-axis, and thus decrease the erosion of studded blocks 250.

Although flow diverters 300 and 310 may also experience erosion, replacement of blind flanges 236 and 240 is much easier and less expensive than replacing bridge connector header 230, short spools 238 b, and/or studded blocks 250.

It will be understood by one of ordinary skill in the art that the placement and configuration of diverters 300 and 310 is exemplary and illustrative only. Flow diverters could also be placed within frac tree 290 or at any other location within the dual spool connection disclosed herein or other similar components which may be used for the flow of abrasive, corrosive, or otherwise deleterious fluids.

As one additional exemplary embodiment, as explained in greater detail in the Sizemore '907 application, valves 102 a and 102 b shown in FIG. 1 of the present application may be replaced with a frac manifold isolation tool. One exemplary embodiment of such a tool is well configuration unit 1210, as shown in FIG. 5-7 . Well configuration unit 1210 may comprise two concentric mandrels, an inner 1255 and an outer 1250. Inner mandrel 1255 comprises a lower end which is connected to compression member 1700.

As described in further detail below, the two mandrels 1255 and 1250 are moved together by the setting cylinders 1220 and 1225 to position the cup tool 1260 at the pack off location below bridge connector header 1230, as shown in FIG. 7 .

The inner mandrel 1255 can be moved independently of the outer mandrel 1250 by a second hydraulic setting tool 1625. Second hydraulic setting tool 1625 comprises hydraulic cylinders 1630 and 1635, which are connected to upper plate 1640. Hydraulic cylinders 1630 and 1635 comprise outer housings 1628 and 1629 respectively, which are connected to upper plate 1640. Hydraulic cylinders 1630 and 1635 also comprise rods 1626 and 1627 respectively. Rods 1626 and 1627 each comprise a lower end, each of which is connected to lower plate 1245.

In operation, improved well configuration unit 1210 begins in the position shown in FIG. 5 , with cup tool 1260 located above bridge connector header 1230. In this position, fluid is free to flow through bridge connector header 1230. The position of the cup tool is shown in more detail in FIG. 6 .

When the operator desires to seal bridge connector header 1230, hydraulic fluid is injected into the upper portion of hydraulic setting cylinders 1220 and 1225, thereby forcing rods 1222 and 1227 downward. Due to the connection between rods 1222 and 1227 and lower plate 1245, as well as the connection between lower plate 1245 and mandrel head 1251, the downward movement of rods 1222 and 1227 causes outer mandrel 1250 to move downward through bridge connector 1230 and into lower spool 1240 to the point that cup tool 1260 is located below the “T” junction of bridge connector header 1230 as shown in FIG. 7 . In addition, due to the connection between rods 1626 and 1627 and upper plate 1640, inner mandrel 1255 and compression member 1700 also move downward towards lower spool 1240.

Once the cup tool 1260 has been positioned at the pack-off location, and the operator desires to engage seals 1265, hydraulic cylinders 1630 and 1635 are pressurized such that rods 1626 and 1627 move upwards, or away from the cup tool 1260, which causes the inner mandrel 1255 to move upward relative to the outer mandrel 1250. When this happens, upper surface 1703 of compression member 1700 contacts the lower surface of gage ring 1261 of cup tool 1260. Because the upper surface of gage ring 1261 contacts seals 1265, continued upward movement of inner mandrel 1255 and compression member 1700 causes gage ring 1261 to compress seals 1265, with the result that seals 1265 are extruded outward and form a seal within lower spool 1240 and/or the inner surface of bridge connector 1230.

Compression member 1700 comprises concave lower surfaces 1701 and 1702, which may serve to divert high-pressure flow and protect the integrity of seals 1265. Lower surfaces 1701 and 1702 may also be convex, planar, or any other configuration, provided that the surface(s) divert the fluid flowing through lower spool 1240 and/or bridge connector 1230 to travel in a direction other than along their common central axis A. The lower surface of compression member 1700 may also comprise more or less than two diverting surfaces. For example, lower surfaces 1701 and 1702 may comprise portions of a flow diverter that is generally conical, such that it comprises one continuous diverting surface. In such a configuration, the generally conical diverting surface may also be concave, convex, planar, or any other configuration.

It is understood that variations may be made in the foregoing without departing from the scope of the present disclosure. In several exemplary embodiments, the elements and teachings of the various illustrative exemplary embodiments may be combined in whole or in part in some or all of the illustrative exemplary embodiments. In addition, one or more of the elements and teachings of the various illustrative exemplary embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.

Any spatial references, such as, for example, “upper,” “lower,” “above,” “below,” “between,” “bottom,” “vertical,” “horizontal,” “angular,” “upwards,” “downwards,” “side-to-side,” “left-to-right,” “right-to-left,” “top-to-bottom,” “bottom-to-top,” “top,” “bottom,” “bottom-up,” “top-down,” etc., are for the purpose of illustration only and do not limit the specific orientation or location of the structure described above.

In several exemplary embodiments, while different steps, processes, and procedures are described as appearing as distinct acts, one or more of the steps, one or more of the processes, and/or one or more of the procedures may also be performed in different orders, simultaneously and/or sequentially. In several exemplary embodiments, the steps, processes, and/or procedures may be merged into one or more steps, processes and/or procedures.

In several exemplary embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Moreover, one or more of the above-described embodiments and/or variations may be combined in whole or in part with any one or more of the other above-described embodiments and/or variations.

Although several exemplary embodiments have been described in detail above, the embodiments described are exemplary only and are not limiting, and those skilled in the art will readily appreciate that many other modifications, changes and/or substitutions are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes, and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, any means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Moreover, it is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the word “means” together with an associated function. 

1. A flow component comprising: a conduit comprising a central longitudinal axis; a first surface substantially orthogonal to the central longitudinal axis; a flow diverter comprising a second surface configured to divert fluid flowing through the conduit to flow in a first direction which is not along the central longitudinal axis.
 2. The flow component of claim 1, wherein the second surface is concave.
 3. The flow component of claim 2, wherein the second surface is substantially conical.
 4. The flow component of claim 1, wherein the second surface is convex.
 5. The flow component of claim 1, wherein the first surface comprises the inner surface of a blind flange upon which the flow diverter is mounted.
 6. The flow component of claim 1, wherein the first surface comprises the lower end of a mandrel.
 7. The flow component of claim 1, wherein the flow diverter further comprises a third surface configured to divert fluid flowing through the conduit to flow in a second direction which is different from the first direction and not along the central longitudinal axis.
 8. The flow component of claim 7, wherein the second surface and the third surface are both concave. 